Method of breaking petroleum emulsions



Patented Nov. 28, 1933 mr'rnonor' 'l' G IONS Truman B. Wayne, Houston, Tex.

This invention relates to a process of resolving petroleum emulsions of the character commonly encountered in the production, handling and refining of petroleum.

The principal object of this invention is to provide an improved process and reagents for treating petroleum emulsions to separate them into their component parts of oil and water.

, This application is, in part, a division of my copendmg application Serial No. 539,125, filed May 21, 1931.

Thepresent process consists in subjecting a petroleum emulsion of the water-in-oi1 type, to the'action of a small proportion of a complex organic condensation product of high molecular weight, resembling somewhat the synthetic resins ways as, for example, by retarding the condensation reactions by the presence of an interfering substance, usually a hydrophilic colloid and/or a solvent which increases its miscibility inwater; or through the substitution of certain groups which'prevent the formation of hard, insoluble resins, and increase the solubility inwater and/or impart a marked hydrotropic efiect tothe fin- 'ished product.

While the herein described series of complex condensation .products resemble very closely a modified synthetic resin or plasticizing agent, they are likewisesimilar in composition to the more complex dye-stufi's, and may be either acidic or basic, depending upon the nature and proportions of the various groups introduced and maybe soluble in either water or oil. depending again on the nature of the completed condensation product, and in certain instances may; have.

a pronounced hydrotropic efiect and thus amines, amides,

cium and Drawing. Application my 31, m:

s 891181 No. 614,615

many of the properties of a mutual solvent for water and oil.

My broad idea-contemplates the use of a resolving agent having the general characteristics above described, prepared from various combinations of organic groupings producedln various ways. I attribute the effectiveness of this new type of compound to its high colloidality, coupled with its very pronounced hydrotropic eifect, resulting in a very marked action at the interfaces of a water-ln-oil emulsion.

While an attempt will be made to define the course of the various chemical reactions involved in the preparation of ;these products. and approximately state their composition, it is to be 05 understood, however. that the invention is not dependent on any theory herein expressed as to the course of the reactions or as to the composition of the products except as defined in the appended claims.

As stated above. a composition of the desired properties may be prepared by substituting certain groups in the complex organic condensation products prepared by the reaction of organic compoundscontaining resinophore groups. For example, the condensation product of synthetic resin type may be modified by the introduction of one or more organic groupings selected from the group comprising alkyl, cyclo-alkyl, aralkyl,

sulfonic, and carboxyl groups. In some ingo stances, the modifying agent may be a detergent body. Specifically, the modifying a ent may be an acid selected from the group comprising organic soap-forming sulfonic, carboxylic, and sulfo-carboxylic acids, or their salts, esters or amides. Further, modified fatty acids and residues from modified fatty acids may constitute modifying agents. Other specific compounds suitable for use are indicated below and it will be noted that in many instances the final'complex condensation product employed as the resolving agent may contain several modifyi'ng roupings.

In addition to the features which characterize thisnew type of compound which are setforth 9.5

aboveitistobenotedthatmanyoftheproducts are capable of undergoing sation with alkalis. Moreover, of the complex. condensation products are very-stabletoward cal- 1" w salts, and may be 10 fully used in relatively small proportions on petroleum emulsions which contain natural hard waters in a finely emulsified condition, and which do not readily respond to treatment with the usual commercial resolving compounds based on modified fatty acids, because of the formation of water-insoluble, oil-soluble calcium and magnesium soaps.

introducing groups or radicals which act as modifying agents, as previously stated.

The organic amines used in the preparation of products that are useful for my purpose may be selected from the general class known as aromatic amines, or arylamines, and includes aniline and its homologues, and the corresponding naphthylamines, etc.

The aliphatic hydrocarbons used may be selected from the various polyhydric alcohols, aldehydes, and acids of the aliphatic series which are known to undergo resinifying reactions with the arylamines. For instance, aliphatic aldehydes such as formaldehyde, acetaldehyde, or butyraldehyde, and their polymerization products may be used. The higher alcohols of the aliphatic series and the various polyhydric alcohols and their ethers are alsosuitable'for my purpose. The higher fatty acids c ntaining more than eight carbon atoms may also be used. In'

this case, resinification occurs through the interaction of the amino group of the aromatic amine and the carboxyl group of the fatty acid, followed by polymerization of the compound so formed.

In order'to illustrate specifically the new type of complex condensation product contemplated for use in accordance with the present invention, 1 have, set forth below several examples of the type of product suitable for use. However, it is to be understood that I do not confine myself to the specific chemicals, or proportions thereof; set forth in these examples, as it will be readily. apparent that equivalents ofthese specific chemicals and their substituted derivatives, and other proportions, may be employed without departing from the spirit of the invention or the scope of the appended claims. My broad idea contemplates the formation of condensation products similar to the well known synthetic resins and plastics formed by the condensation reactions between chemical bodies or groups of the character mentioned above, but differing from these insoluble resins in that they are highly colloidal and usually water-soluble as a result of the incorporation'therein of organic residues by nuclear substitution and condensation reactions which form complex products of very high molecular weight possessing the desired colloidalitlv and wetting properties.

The distinguishing structural characteristic of the following reaction products of an arylamine and one or more chemical individuals of the ali-" phatic series, is the presence of an amino group or its residue after having one or both of its hydrogen atoms replaced by acyl residues, or otherwise linked with alkyl residues or polymerized products thereof derived from members of the aliphatic series that are capable of undergoing resinifying reactions. In fact, compounds of this type may be regarded as acylated arylamines of the general formula wherein R stands for a substituted or unsubstituted cyclic or polycyclic aryl group, and R1 and R2 represent alkyl or other aliphatic residues, or

condensation products of these with aromatic hydrocarbons. Very effective compounds are prepared by having either R1 or R2 represent an alkyl group having not more than five carbon atoms, while'the remaining position is occupied by a long straight chain aliphatic radical, or a condensed body of very high molecular weight which contains aliphatic alkyl groups as side chains. (See Examples 4 and 5 below.)

A further embodiment of the invention is to combine the resinous, acylated amino derivatives above described with primary or secondary alkyl amines and their hydroxylated derivatives to form long chain tertiary amine salts of very pronounced wetting properties. As a prerequisite for .this, it is necessary that carboxyl and/or sulfonic groups be present in one or more of the R, R1, R2 positions to act as acylating agents for the alkyl amine. The alkyl amine alreadycontains one or two alkyl or hydroxy alkyl groups containing not more than five carbon atoms each, and upon Example 1 An aromatic amino, such as aniline oil, is first sulfonated and the resulting product reacted with v a polyhydric alcohol. In the preferred practice of this embodiment of the invention, 300 parts of 98-100% sulfuric acid are run into a jacketed reaction kettle and 100 parts of aniline oil are cautiously added. The mixture, consisting of aniline sulfate with an excess of sulfuric acid, is heated to 180-200 C. by circulating heated oil or steam in the jacket, and maintained at this temperature until converted into water-soluble form.

While still warm enough to prevent crystallization of the sulfonated material, the acid solution hol, preferably ethylene glycol or diethylene glycol while stirring constantly. A thick, viscous, soft resin is formed, the-properties of which can be varied by the temperature at which the reaction occurs and the duration of the heating period. In preferred practice, the heating should be conducted at about 100 C. until a soft resin of viscosity is obtained, which product is water-soluble.

Example 2 Sulfonated aniline is prepared and added to a p lyhydriq alcohol in the manner set forth in Example 1, after which from 10 to 60 parts ofan is slowly run into'200 parts of a polyhydric alcoaldehyde solution, such as a 40% formaldehyde solution, are added slowly while stirring constant- I 1y. A very viscous, soft resin is formed which is water-soluble. Care must be taken to avoid too prolonged heating and employing an excessive amount of formaldehyde since an insoluble resin may be formed in such cases.

Example 3 A sulfonated resin prepared as in Examples 1 or 2 is mixed with a molecular quantity of a higher fatty acid, such as oleic acid, and warmed to 50-100 C. for 2 hours. A complex, water insoluble, condensation product forms which is very sticky and viscous. Upon diluting with water and boiling, sulfuric acid is split OE and the resinous ,upperlayer is withdrawn and converted to its potassium or ammonium salt, or is heated with an aliphatic or alkylene amine to convert it to its corresponding amino derivative. The product so produced is very soluble in petroleum products, and formshighly colloidal water solutions.

ll'ammple 4 1 mol each of aniline oil, oleic acid, and

acetaldol, are heated to 50 C., and 500 parts of 98% sulfuric acid are slowly and cautiously added while maintaining the temperature at 40-60 C.

After all of the acid is in, the mass is heated at C. for an hour, and flnallyat 100 C. for an hour or until a thick, oily, resin is formed which gives no test for free aniline or aldehyde. The mass is diluted with anequal volume of water, heated to boiling, and the upper layer that separates is withdrawn and converted into its potassium or ammonium salt, or into an amino derivaetive as described in Example 3.

Some of the products prepared in accordance with the examples set forth above are very active de-emulsifyingagents for water-in-oil emulsions, and may be used as such. However, more complex condensation products may be prepared in several' ways, as indicated below, and are preferred pare a separate batch of a nuclear-substituted according to any of the well known methods of preparing such chemicalbodies, and condense one part of the soluble resins described above with from 1 to 10 parts of the substituted aromatic acid, the proportions of reacting materials employed varying with the type of resin treated. As the unwashed derivatives are usually used in these condensing reactions, they are often sufiiciently acidic to condense uponwarming and agitating but, if desired, sufllcient oleum or chlorosulfonic acidmay be added to complete the condensation. While the acid mass resulting from the treatment may be employed it is also possible, and sometimes advantageous, to employ an ester, salt, or amino derivative.

. The following example is illustrative of this embodiment of the invention:

EmmpZe 5 100 parts of a water-soluble resin as prepared according to any oi the above examples are conamine involves acylation of the amine through densed with 500 parts of butylnaphthalene sulfonic acid, prepared as follows:

100 parts of 98 per cent sulfuric acid are run into a jacketed reaction kettle and heatedto a temperature of approximately 160C. 500 parts '80 of melted naphthalene are slowly run into thev heated acid and the temperature is raised to ap-' proximately 180 C. and the mass maintained at such temperature for about two to three hours, or until the naphthalene has become' intensively sulfonated, this possibly being brought about through the substitution of two or three sulfonic groups.

800 parts of 98 per cent sulfuric acid are slowly run into a coil-equipped reaction vessel containing 500 parts of normal butyl alcohol, the temperature being maintained below 85 C. The acid butyl sulfate so formed is then added to the naphthalene sulfonic acid, which previoi'sly has been cooled to about 100-125 (1., over a-period of two hours, and the heating is continued for an additional period of three hours, if necessary, to v complete the alkylation. o

The above product may also be prepared by mixing the alcohol with the naphthaleneand slowly adding the sulfuric aciduntil alkylation is complete. Then the balance of the sulfuric acid is added, and the sulfonation is accomplished at elevated temperatures.

Instead of n-butyl alcohol, any of the other primary alcohols or a secondary alcohol, such as isopropanol, may be used.

500 .parts of the resulting acid mass are then condensed at approximately 80 to 100 C. with 100 parts of the-soft synthetic resin prepared ac- 1-10' cording to Examples 1, 2, 3, or 4 to form a very complex condensation product of extremely high molecular weight which is unusuallyeflicient as a treating reagent for petroleum emulsions.

The acid mass produced may be used as such or, as is sometimes found to be advantageous, it maybe converted into its sodium, potassium, or ammonium salt, or into its ester by combination with alcohols. V

Example 6 A complex condensation product such as that prepared in accordance with the preceding example may be further condensed with a suitable compound or grouping to provide a resultin water or oil soluble amino derivative. For example, the acid condensation product may be condensed with primary, secondary, ortert iary aliphatic amines-or alkyl substituted aromatic amines which yield water or oil soluble derivatives. In preferred practice I employ an alkyl amine, particularly one which contains one or more hydroxylated aliphatic groups, such as mono-, di-, or tri-ethanolamine. Products of this type have been found tobe unusually efiective agents for resolving petroleum emulsions.

As a specific example of this embodiment of the invention, 500 parts of the acid condensation product prepared according to the method covered by Example 5, which may be freed from its excess of mineral acid by any well known method, are combined with 50 parts of diethanolamine.

The reaction between the acidic condensation product and an aromatic primary or secondary replacement of one or both ofthe hydrogen atoms of the amino group, .NH2. This is efiected 5y heating the mixture at elevated temperatures.

In the case of an aliphatic mine, for in- 159 stance a di-alkylamine, the reaction product may be simply the substituted ammonium salt of the type wherein R is alkyl, R1 is alkyl or H, R2 is the radical attached to the sulfonic or carboxyl group, X..OH, pf the acidic resinoid body, and N is the nitrogen atom.

The water solubility of the product is usually increased by condensing the acidic resinoid body with aliphatic amines or aromatic amines-containing alkyl groups in the side-chain according to formula (1). On the other hand. products of the R.R1.N.X.R2 type indicated in reaction (2) are very soluble in petroleum products, and form colloidally hydrated aqueous solutions.

Where much larger than stoichiometrical proportions of the acidic condensation product are used, a third type of reaction involving esterification of the hydroxyl groups of the hydroxylated aliphatic amine also occurs. This may occur simultaneously with the acylation of the amino group, and thus provides a very complex condensation product which is a highly eflicient demulsifler for petroleum emulsions. The reaction would then probably take place according to the following general scheme:

C2H40H CzHr-OX-Rg (3) EN +3Rz-X-OH Ri-X-N +3Hz0 Wherein R2 is the radical attached to the sulfonic or carboxyl group, .X.0H, of the acidic resinoid body employed as an acylating agent,

and N is the nitrogen atom.

Such condensation products may be exemplified by the following type formula:

A-OX-R:

A-OX-Rz wherein R2.X is the resinoid radical attached to the nitrogen atom, N; and A.OX.R2 is the ester produced by esterification of the hydroxyl groups of the alkyl radical, A.

It is obvious that many permutations and combinations of substances may be prepared from the various reactive bodies known to undergo resinification, and that only afew examples can be given in the specification. It is also obvious that two or more of the resins produced may be further condensed and then combined with a nuclear-substituted aromatic sulfonic acid, and that alkylation and sulfonation can often be conducted simultaneously with resinification in many cases.

Proportions of reacting substances, temperatures, time of heating, etc., are specified in some of the preceding examples while more general directions only are given in others. Obviously, many permutations and combinations in proportions of reacting bodies are made possible by varying the time of heating and/or the temperatures used. For example, if molecular proportions of a polyhydric alcohol and an aldehyde,

or an aromatic amino sulfonic body. and an aldehyde, are heated at a certain temperature for 12 minutes to form a water-soluble condensation product, it is obvious that if only one-half mol of aldehyde is used, the heating must be extended or the temperature raised, or both, to obtain a condensation product of the same physical characteristics. Conversely, if two mols of aldehyde are used either the temperature must be reduced or the time of heating shortened, or both, to prevent the condensation from proceeding to the point where insoluble resins are obtained. The properties of the particular aldehydes, alcohols, fatty acids, etc., used will likewise infiuence the procedure employed in the preparation of these soluble resinous bodies as will also the nature of the organic residues present in substituted derivatives of the various polyhydric alcohols, aldehydes, amines, etc. These various considerations, however, are within the knowledge and practices of the trained organic chemist and will be readily understood by those skilled in the art.

Where reference is made in the appended claims to carboxyl and sulfonic groups it is to be understood that this refers to the presence of COOH and 802.011 groups respectively, and also to the products formed when they are neutralized by a metallic base, ammonia, or organic amine. Equivalents of these groups are also contemplated.

The term water-soluble is used to include the property of forming colloidally hydrated aqueous solution.

The improved treating agents prepared inaccordance with the present invention are used in the proportion of one part of-treating agent to from 2,000 to 20,000 parts of petroleum emulsion, either by adding the concentrated product directly to the emulsion or after diluting with water or oil in the conventional manner. The

treating agents may be used in any of. the nu- 1. The process of resolving water-in-oil emul- .sions which comprises adding thereto a complex condensation product of .thc modified synthetic resin type prepared from a sulfonated aromatic amine and one'or more aliphatic bodies containing resinophore groups.

2. The process of resolving water-in-oil emul sions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine and a polyhydrlc alcohol of the aliphatic series.

3. The process of resolving water-in-oil emulsions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine and an aldehyde of the aliphatic series.-

4. The process of resolving water-in-oil emulsions which comprises adding thereto a'complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine, a polyhydric alcohol, and an aldehyde of the aliphatic series.

5. The process of resolving water-in-oil emulsions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine, a polyhydric alcohol, an aldehyde of the aliphatic series, and a fatty acid having more than eight carbon atoms.

6. The process of resolving water-in-oil emulsions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine, one or more aliphatic bodies containing resinophore groups, and a nuclear-substituted aromatic sulfonic acid.

7. The processof resolving water-in-oil emulsions which comprises adding thereto a complex condensation product '01 the modified synthetic resin type prepared from a sulfonated aromatic amine, a polyhydric alcohol of the aliphatic series, and a nuclear-substituted aromatic sulionic acid.

8. The process of resolving water in-oil emulsions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a. sulfonated aromatic amine, an aldehyde of-the aliphatic series, and a nuclear-substituted aromatic sulfonic acid.

9. The process of resolving water-in-oil emulsions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine, a polyhydric alcohol, an aldehyde of the aliphatic series, and a nuclear-substituted aromatic sulfonic acid. 10. The process of resolving water-in-oil emulsions which comprises adding thereto a complex condensation product of the modified synthetic resin type prepared from a sulfonated aromatic amine, a-polyhydricalcohol, an aldehyde of the aliphatic series, a fatty acid having more than eight carbon atoms, .anda nuclear-substituted aromatic sulfonic acid.

11. The process of resolving water-in-oil emulsions which comprises adding thereto a treating agent comprising a water-soluble derivative of the condensation product of a sulfonated aromatic amine, a polyhydric alcohol, and an aromatic compound selected from the group comprising aromatic sulfonic acids and nuclear-substituted derivatives thereof, said water-soluble derivatives being a salt, ester, or amino derivative thereof.

12. The process of resolving water-in-oil emulsions which comprises adding thereto a treating agent comprising a complex condensation product of a sulfonated aromatic amine, a polyhydric alcohol, an aldehyde, and an aromatic compound selected from the group comprising aromatic sulionic acids and nuclear-substituted derivatives thereof.

13. The process of resolving water-in-oil emulsions which comprises adding thereto a treating agent comprising a water-soluble derivative of the condensation product of a sulfonated aroamine of the general type and an aromatic compound selected from the group comprising aromatic sulfonated acids and nuclear-substituted derivatives thereof, said water-soluble derivative being a salt, ester, or amino derivativethereof.

l 14. The process of resolving water-in-oil emulsions which comprises adding thereto a treating agent comprising a complex condensation product of a sulfonated aromatic amine, a polyhydric alcohol, an aldehyde, a nuclear-substituted aromatic sulfonic acid, and an alkylamine containing a hydroxylated aliphatic group.

15'. The process of resolving water-in-oil emul sions which comprises adding thereto a treating agent comprising a water-soluble derivative of the condensation product of a sulfonated aromatic amine, a polyhydric alcohol, a compound selected from the group consisting of aldehydes and aldols, a fatty acid having more than eight carbon atoms, and an aromatic compound selected from the group comprising aromatic sulfonic acids and nuclear-substituted derivatives thereof, said water-soluble derivative being a salt, ester, or amino derivative.

16. The process of resolving water-in-oil emulsions which comprises adding thereto a treating agent comprising a complex condensation product of a sulfonated aromatic amine, a polyhydric alcohol, an aldehyde, a fatty acid having more than eight carbon atoms, a nuclear-substituted aromatic sulfonic acid, and an alkylamine containing a hydroxylated aliphatic group. 17. The process of resolving water-in-oil-mulsions which comprises adding thereto an acylated non-hydroxy amine of the general type wherein the radicals R, R1, and R2 are selected from the group consisting of substituted and unsubstituted aryl groups, non-hydroxy alkyl groups, and residues from aliphatic acids containing more than eight carbon atoms, .and condensation products of these with aromatic hydro carbons.

matic amine, a polyhydric alcohol, an aldehyde,

1 18. The process of resolving water-in-oil emulsions which comprises adding thereto the condensation product of a non-hydroxy alkylamine and a resinoid body comprising an acylated wherein the radicals R, R1, and R2 are selected from the group consisting of substituted and unsubstituted aryl groups, non-hydroxy alkyl groups, and residues from aliphatic acids containing more than eight carbon atoms, and condensation products of these with aromatic hydrocarbons.

19. The process of resolving petroleum emulsions which comprises adding thereto a. treating agent comprising a water-soluble substituted ammonium salt of the general type RRrI-IN-X-OH-Ra wherein R is alkyl, R1 is alkyl or hydrogen, NH is an imino group, X'OH is a carboxyl or sulfo Q) group, and-R2 is a complex resinoid body, said resinoid body being characterized by the presence of an amino group or its residue linked with residues from members of the aliphatic series.

20. The process of resolving petroleum emulsions which comprises adding thereto a treating agent comprising an oil soluble substituted amine of the general'type RRIN'X'RSZ, wherein R is alkyl, R1 is alkyl or hydrogen, N is a nitrogen atom, X is a residue from a sulfo or carboxyl group, and R2 is a complex resinoid body, said resinoid body being characterized by the presence of an amino group or its residue Linked with residues from members of the aliphatic series.

21. The process of resolving petroleum emulsions which comprises adding thereto a treating memes agent comprising a substituted mine of the general type A.OX.R: wherein AOX-Rz is the ester radical produced by esterification of the hydroxyl groups of the alkyl radical or radicals A, N is a nitrogen atom, and Rz-X is the residue from the complex resinoid body Rz-X-OH, said resinoid body being characterized by the presence of an amino group or its residue linked with residues from one or more members of the aliphatic series.

TRUREAN B. WAYNE. 

